Apparatus for production of mouline yarns

ABSTRACT

Process and apparatus for the production of repeatedly compressed mouline carpet yarns in which the yarn is guided through a compression crimping chamber and then corded with guiding each of the yarns under identical conditions through large angle which is the same for each of the yarns.

United States Patent Gemeinhardt [4 1 Mar. 28, 1972 [54] APPARATUS FORPRODUCTION OF [56] References Cited UNlTED STATES PATENTS [721 lnvemo"Herman" Gemeinhardl, Elsenfeld 3,255,507 6/1966 McCaskill 1.28/1 .6

y 2,882,675 4/1959 Tingas [73] Assignee: Glanzstoff AG, Wuppertal,Germany 19 11/1962 3,164,882 1/1965 Rosenstem et al [22] Filed: May 23,1969 3,218,675 11/1965 Hendrix 3,238,591 3/1966 Rosenstein [211 827,2413,382,657 5/1968 Horvath 3,479,810 11/1969 Eshuis ..57/140 30 F A 11 11P 1 it D 1 l 1 orflgn pp ca on r or y a a Primary Examiner-John PetrakesMay 29, 1968 Germany ..P 17 60 51 1.7 Artorney-Johnston, Root, OKeeffc,Keil, Thompson & Shurtleff [52] US. Cl. ..57/34 HS, 23/16, 57/90,

57/ 57 s [57] ABSTRACT 1 Int. Process and apparatus for the productionof repeatedly com- 1 1 FieId Search 34 157 157 pressed mouline carpetyarns in which the yarn is guided through a compression crimping chamberand then corded with guiding each of the yarns under identicalconditions through large angle which is the same for each of the yarns.

10 Claims, 4 Drawing Figures Patented March 28,1972 3,651,630

2 Sheets-Sheet l 27 FIG.1

II E i gs 13 E l2 [NV/5N! OR HERMANN GEMEINHARDT Patented March 28, 19723,651,630

2 Sheets-Sheet 2 FIG. 4

HERMANN GEMEINHARDT ww ww APPARATUS FOR PRODUCTION OF MOULINE YARNSINTRODUCTION So-called mouline yarns are widely used in the manufactureof floor coverings. These are yarns that have been twisted together fromseveral, preferably three, individual yarns each of which has been dyedin a different colour after texturing. Unfortunately, the individualnature of yarns such as these gives rise to difficulties in that evenminor deviations in the regularity of the structure are sufficient tocause differences in the dye finish of the end yarn so great that theyarn cannot be used. Irregularities of this kind occur for example incases where the tension in the individual yarns differs where they meetat the cording station.

This problem is well known and various attempts have been made toprevent this phenomenon known among experts as the core effect. Thus, ithas been proposed, with texturing in mind, to arrange in front of thetake-in mechanism of the compression chamber a yarn comb which engagesdeeply between the rollers and into which the yarns are individuallyplaced. Means for electrostatically spraying the incoming and outgoingyarn should also be provided, their object being to make it easier forthe yarns issuing from the compression chamber to be separated. Apartfrom the considerable outlay involved, this process gives rise tovarious difficulties, in particular in inserting the yarns and inseparating them because this arrangement is unable to avoid the wellknown matting together of the individual yarns in the compressionchamber. In addition, the unfavorable filling of the compression chamberresulting from the distance necessary between the incoming individualfilaments produced an unsatisfactory crimp. Tensions are generatedduring separation of the filaments as a result of the matting of theindividual filaments, which was clearly promoted by the interval betweenthe filaments during insertion, and this could not even be eliminated byparallel winding or even spreading of the filaments before the cordingstage. Thus it is not possible'to produce a satisfactory mouline yarnwithout the so-called core effect.

DESCRIPTION OF THE INVENTION It has now surprisingly been found that avery uniform mouline yarn can be produced in a single operationproviding the filaments are guided strictly parallel to one another intothe compression crimping chamber without any intervals or gaps betweenthem. The crimped readily separable filaments issuing from thecompression chamber must then be guided a minimum distance of about 0.8m. at some distance from one another, bent through an extremely largeangle behind a last delivery unit and then guided through a yarn guideacting as the cording station to the twisting spindle.

Accordingly, the invention provides a process for the production ofrepeatedly compressed mouline yam comprising the steps of guidingindividual yarns for forming the mouline yarn parallel to one anotherwithout any gaps or spaces between the individual yarns into and througha compression chamber; separating the yarns after they leave thecompression chamber; guiding the yarns at a distance of at least 3 mm.apart from one another through a delivery means; guiding each of theyarns under identical conditions through a large angle which is the samefor each of the yarns; passing the yarns through a common cordingstation; and winding the yarns together onto a cording spindle.

In a simplified process, the crimped, individual yarns, after leavingthe compression chamber, are initially wound parallel to one anotheronto a cylindrical bobbin from which they are guided over a separatingand guiding means to the cording spindle in the manner described. This,however, does involve more in terms of machinery and time. In addition,the uniformity with which the yarns are guided to the cording stationmay in some cases be affected.

The yarns travelling through the unit by which they are deflectedrespectively at a large angle form the comer edges of a symmetricpyramid whose transverse cross-sections form strictly equal-sidedgeometrically similar polygons, the number of sides of which depend uponthe number of yarns.

The compression means is preferably divided into two chambers precededby heating means. Preferably the yarn separating means is in the form ofa yarn comb, arranged after the compression chamber. Preferably thecording station comprises a cording polygon having a plurality of yarnguides corresponding in number to the number of individual filaments oran integral multiple thereof, the yarn guides being arranged at thevertices of an equilateral polygon; an additional collecting yarn guidecommon to all the individual yarns arranged at a distance from the planedefined by one said plurality of yarn guides at the center of theequilateral polygon and in front of the latter as seen in the directionof yarn travel; and a balloon yarn guide symmetrically arranged withrespect to collecting yarn guide and on the opposite side of theequilateral polygon to the collecting yarn guide.

The take-in rollers of the compression means have a hollow groundsection which begins 0.5 to 1 mm. from the edges of the rollers andreaches a depth of from 0.008 to 0.06 mm. and preferably from 0.01 to0.03 mm. in the middle of the rollers. The depth of the hollow groundsection is governed by the thickness and its width by the number ofyarns to be simultaneously introduced into the compression chamber. Thedepth of the hollow ground section has to be selected from within thelimits specified in such a way that every yarn is engaged without anyslip. With thin yarns in particular, only one of the two rollers needhave a hollow-ground section, whilst the second is plane-ground.Although it is possible to grind a flat groove whose depth correspondsto the limits specified above, into the surface of the delivery rollersinstead of having a concave ground portion whose cross-sectioncorresponds substantially to a circular segment, the concave groundportion has proved to be more favorable.

So far as the configuration of the cording polygon is concerned, it hasbeen found that the height of the pyramid defined by the base (definedby the individual yarn guides corresponding to the number of individualyarns) and the apex (the collecting yarn guide and the yarns passingcollectively therethrough), should amount to between 0.2 and 2.0 timesand preferably to between 0.8 and 1.6 times the diameter of the circlecircumscribing the said base. The collecting yarn guide is situatedahead of the polygon forming the base, as seen in the direction of yarntravel. The cording station includes a balloon yarn guide which combinesthe yarn arriving from the individual yarn guides forming the base and,in terms of arrangement, forms the counterpart of the collecting yarnguide. The so-called balloon yarn guide preferably moves up and down insynchronism with the ring rail, but with a shorter stroke, as a resultof which the distance to the base of the cording polygon should bearranged in such a way that the shortest distance between the baseof thecording polygon and the balloon yarn guide is not much shorter than thedistance separating the collecting yarn guide from the latter, and ispreferably no shorter than 0.8 times the distance separating thecollecting yarn guide from the polygon base.

Irrespective of whether the process was carried out in one or twostages, however, it was found in every test that strict parallel guidingthrough the compression chamber and maintaining the distances specifiedfor the arrangement of the yarn guides in the cording polygon togetherwith the arrangement of the cording station, are necessary for producinga uniform yarn.

DESCRIPTION OF THE DRAWINGS An apparatus suitable for carrying out theprocess according to the invention is described in detail with referenceto the accompanying drawings, wherein:

FIG. 1 is a simplified illustration showingthe delivery of the yarnsthrough the cording polygon and the balloon yarn guide to the ringtwisting spindle;

FIG. 2 is a section through, and FIG. 3 a plan view of, thehollow-ground take-in rollers of the compression chamber; and

FIG. 4 is an elevational view showing how the yarn is guided from thelast delivery roller to the cording polygon and thence to the balloonyarn guide.

DESCRIPTION OF ILLUSTRATED EMBODIMENT Means for the delivery of yarns tobe compressed from supply bobbins through a compression chamber,preferably provided with two compartments, are known, and FIG. 1 merelyillustrates the second stage of the aforedescribed simplified embodimentof the invention. Supply bobbins 2 and 3 are rotatably mounted on atake-off stand 1 in such a way that the yarns 5 are run offtangentially. The yarns run through a traversing yarn separator 4arranged just contiguous to the supply bobbins and are delivered fromthis separator to a yarn heating means 26 and a compression crimpingchamber 27 and thereafter to a separating comb 6 which spaces them atthe predetermined distance apart. They then pass over a guide rollers 7to a delivery roller 8 and a separating roller 8' and thence to acording polygon unit 9. As shown in FIG. 4, this comprises a collectingyarn guide 15 and yarn guides 16 which define the base of the cordingpolygon and which correspond in number to the number of yarns or to anintegral multiple thereof. The collecting yarn guide 15 is arrangedexactly perpendicularly above the center point of the base defined bythe yarn guides 16, whilst the cording polygon as a whole is arrangedabove a balloon yarn guide 10 in such a way that it too lies exactlyperpendicularly beneath the center of the base of the cording polygondefined by the yarn guides 16. In this way, the balloon yarn guidebecomes a clearly defined cording station ensuring the uniformity of theyarn in the course of formation. The combined yarns are guided from theballoon yarn guide in the usual way through a ring traveller 13 on atwisting ring 12 to a winding 11 on a winding spool or tube mounted onthe twisting spindle 14. The twisting ring 12 reciprocates vertically.It may be mounted on a conventional, vertically reciprocated ring railbench. The conventional vertical reciprocating drive thereof isdesignated symbolically by the arrow 29. The balloon yarn guide 10reciprocates vertically in synchronization with the twisting ring 12 butwith a shorter stroke. It is motivated also by a conventional drivedesignated symbolically by the arrow 28.

The configuration of the compression chamber take-in rollers is shown inmore detail in FIGS. 2 and 3. Take-in rollers 19 and 20 have narrowcylindrical edges 24 and between them a symmetrical hollow groundportion 23 which forms a symmetrical bi-convex hollow nip 25 when theedges of the rollers are in contact with one another. Following theusual procedure, the two take-in rollers 19 and 20 are arranged in thecompression chamber so that the points at which the edges of thesurfaces of the two rollers 19 and 20 touch one another are covered byjaws 21 and 22 extending across the nip of the rollers. The dimensionsof the hollow duct 25 are such that even in the middle the yarn passingthrough is sufficiently compressed to deliver the yarns uniformly intothe compression chamber.

FIG. 2 shows the introduction of the yarns into the compression chamber.They are introduced parallel to one another through a yam guide means 18arranged between the two take-in rollers 19 and 20. The yarns retaintheir strictly parallel disposition on account of the shape of thesurface of the rollers.

Surprisingly, this strictly parallel guide arrangement extends into thecompression chamber too so that the compressed or crimped filaments 5,5' and 5" issuing from it are still strictly separate from one anotherand have not matted together.

If the number of yarn guides 16 is an integral multiple of the number ofyarns 5,5, 5", the yarns have to be inserted into the yarn guides 16 insuch a way that the same interval remains between them. Accordingly, iffor example there are six yarn guides 16 and three yarns 5,5, 5",alternate yarn guides 16 are not used. If there are only two yarns 5 and5 two adjacent pairs of yarn guides 16 must remain free.

The effect of the measures provided by the invention was surprising. Ithad been possible in the past by arranging the yarn guides 18sufficiently close to the point at which the takein rollers 19 and 20coincide, to guide the yarns 5,5, 5" through the compression chamber insuch a way that they could be separated again fairly easily. However,the difficulties in dyeing were still impossible to overcome, this beingattributable to the fact that it was impossible to obtain a strictlyparallel passage of the yarn in the compression chamber. Success alsoeluded the attempt to obtain an end product that was uniform in itsdyeability and color distribution even with the aid of the cordingpolygon 9. Only with the combination of hollow-ground take-in rollers 19and 20 in the compression chamber with the strictly parallel guiding ofthe yarn to a delivery roller 8,8 and thence to the cording polygon 9arranged with its axis of symmetry exactly in the spindle axis and abovethe balloon yarn guide, was it possible for the first time to eliminateall the difficulties that had proved so troublesome in the past.

The process according to the invention has proved to be particularlysuitable for treating yarns of organic linear high polymers such aspolyamides and polyesters. Higher-denier, multifilament individual yarnswith a denier of at least 120 are particularly suitable. The denier ofthe individual yarns is preferably not less than 250 to 300 den.,individual yarns which themselves are multifilament yarns being thecomponents for the composite mouline yarn forming the end product. Theindividual filament deniers to be made up lie within the usual limitsand under no circumstances should they exceed 8 to 10 den. It ispreferred to use yarns in which the individual denier is from 3 to 5den. for a denier of at least 250 to 300 den. common to all componentsforming the mouline yarn.

The process according to the invention is illustrated by the followingExamples:

EXAMPLE 1 A yarn of denier 570/32, doubled, was introduced into thecompression chamber by means of a pair of delivery rollers which had awidth of 7.5 mm., a hollow ground portion (concave) of 0.01 mm. beingprovided in both rollers, beginning 0.5 mm. from the edges of therollers. Accordingly, its width was 6.5 mm.

In a second test, a yarn of the same denier quadrupled was guidedthrough the apparatus.

In both cases, it was found that the yarns issued from the compressionchamber in a strictly parallel arrangement and were very easy toseparate.

The yarns were then delivered via appropriate revolving and conveyingmeans to a cording polygon with four yarn guides in its square base andwere then passed on to a cording spindle. The distance of the four yarnguides from one another was mm., whilst the distance of the collectingyarn guide from the base was 90 mm. The cording polygon was arranged insuch a way that the shortest distance between the balloon yarn guide andthe base was mm.

In both cases, a highly uniform yarn was obtained.

EXAMPLE 2 Three yarns of denier l /64 were introduced into thecompression chamber by means of two take-in rollers 10 mm wide which hada deep hollow ground groove 8 mm. wide and 0.03 mm deep. In this case,too, it was found that the yarns moved through the compression chamberin strictly parallel order and, on leaving the compression chamber, werevery easy to separate.

The yarns were then delivered via-appropriate guiding and conveyingmeans to a cording polygon with three yam guides in the base surface,and were then passed on to a cording spin- (He. The distance of thethree yarns guides from one another was 95 mm., whilst the distance fromthe base to the collecting yarn guide was 100 mm. The cording polygonwas arranged in such a way that the shortest distance between theballoon yarn guide and the base was 130 mm.

In this case, too, a highly uniform yarn was obtained.

It is thought that the invention and its numerous attendant advantageswill be fully understood from the foregoing description, and it isobvious that numerous changes may be made in the form, construction andarrangement of the several parts without departing from the spirit orscope of the invention, or sacrificing any of its attendant advantages,the forms herein disclosed being preferred embodiments for the purposeof illustrating the invention.

The invention is hereby claimed as follows:

1. An apparatus for the production of mouline yarn comprising guidemeans adapted to guide individual yarns for the mouline yarn parallel toone another without any gaps between the individual yarns; a compressioncrimping chamber; yarn separating means for separating the yarns afterthey leave the compression crimping chamber; yarn delivery means; meansfor guiding the yarns at a distance of at least 3 mm. apart from oneanother through the delivery means; a cording station formed by acording polygon having an apexial yarn feed guide and a plurality ofyarn guides corresponding in number to the number of individualfilaments or an integral multiple thereof, the latter yarn guides beingarranged at the vertices of a horizontal equilateral polygon; a yarnballoon guide positioned below the horizontal plane of said equilateralpolygon and vertically aligned with the center of the equilateralpolygon; a ring twisting spindle with its ring symmetrically positionedbeneath the collecting yarn guide; means for reciprocating said ring upand down; and further means for reciprocating said yarn balloon guide upand down in synchronism with said ring of said ring twist spindle butwith a shorter stroke, said stroke keeping said yarn balloon guide at aminimum vertical distance from the plane of said horizontal equilateralpolygon of 0.8 times the vertical distance between said apexial yarnfeed guide and said plane of said horizontal equilateral polygon.

2. An apparatus as claimed in claim 1, wherein the compression crimpingchamber includes two take-in rollers, at least one of which has ahollow-ground roller surface.

3. An apparatus as claimed in claim 1 wherein the yarn separating meansis in the form of a yarn comb positioned after the compression crimpingchamber.

4. An apparatus as claimed in claim 1, wherein at least one of thetake-in rollers of the compression crimping chamber has a hollow groundroller surface which commences at from 0.5 to 1 mm. from the edges ofthe roller and reaches a depth of from 0.008 to 0.06 mm. in the middleof the roller.

5. An apparatus as claimed in claim 4, wherein the depth of the hollowground portion is from 0.01 to 0.03 mm.

6. An apparatus as claimed in claim 4, wherein the roller surface of oneof the two rollers is hollow-ground and the other is plane-ground.

7. An apparatus as claimed in claim 1, wherein both take-in rollers ofthe compression crimping chamber has a flat groove which begins 0.5 to 1mm. from the edges of the roller and is from 0.008 to 0.06 mm. deep.

8. An apparatus as claimed in claim 7, wherein the depth of the grooveis from 0.01 to 0.03 mm. deep.

9. An apparatus as claimed in claim 1, wherein the height of the pyramiddefined by the base formed by the said plurality of yarn guides, thecollecting yarn guide and the yarns travelling through, is from 0.2 to2.0 times the diameter of a circle circumscribing the base.

10. An apparatus as claimed in claim 9, wherein the height of thepyramid is from 0.8 to 1.6 times the diameter of the circlecircumscribing the base.

1. An apparatus for the production of mouline yarn comprising guidemeans adapted to guide individual yarns for the mouline yarn parallel toone another without any gaps between the individual yarns; a compressioncrimping chamber; yarn separating means for separating the yarns afterthey leave the compression crimping chamber; yarn delivery means; meansfor guiding the yarns at a distance of at least 3 mm. apart from oneanother through the delivery means; a cording station formed by acording polygon having an apexial yarn feed guide and a plurality ofyarn guides corresponding in number to the number of individualfilaments or an integral multiple thereof, the latter yarn guides beingarranged at the vertices of a horizontal equilateral polygon; a yarnballoon guide positioned below the horizontal plane of said equilateralpolygon and vertically aligned with the center of the equilateralpolygon; a ring twisting spindle with its ring symmetrically positionedbeneath the collecting yarn guide; means for reciprocating said ring upand down; and further means for reciprocating said yarn balloon guide upand down in synchronism with said ring of said ring twist spindle butwith a shorter stroke, said stroke keeping said yarn balloon guide at aminimum vertical distance from the plane of said horizontal equilateralpolygon of 0.8 times the vertical distance between said apexial yarnfeed guide and said plane of said horizontal equilateral polygon.
 2. Anapparatus as claimed in claim 1, wherein the compression crimpingchamber includes two take-in rollers, at least one of which has ahollow-ground roller surface.
 3. An apparatus as claimed in claim 1wherein the yarn separating means is in the form of a yarn combpositioned after the compression crimping chamber.
 4. An apparatus asclaimed in claim 1, wherein at least one of the take-in rollers of thecompression crimping chamber has a hollow ground roller surface whichcommences at from 0.5 to 1 mm. from the edges of the roller and reachesa depth of from 0.008 to 0.06 mm. in the middle of the roller.
 5. Anapparatus as claimed in claim 4, wherein the depth of the hollow groundportion is from 0.01 to 0.03 mm.
 6. An apparatus as claimed in claim 4,wherein the roller surface of one of the two rollers is hollow-groundand the other is plane-ground.
 7. An apparatus as claimed in claim 1,wherein both take-in rollers of the compression crimping chamber has aflat groove which begins 0.5 to 1 mm. from the edges of the roller andis from 0.008 to 0.06 mm. deep.
 8. An apparatus as claimed in claim 7,wherein the depth of the groove is from 0.01 to 0.03 mm. deep.
 9. Anapparatus as claimed in claim 1, wherein the height of the pyramiddefined by the base formed by the said plurality of yarn guides, thecollecting yarn guide and the yarns travelling through, is from 0.2 to2.0 times the diameter of a circle circumscribing the base.
 10. Anapparatus as claimed in claim 9, wherein the height of the pyramid isfrom 0.8 to 1.6 times the diameter of the circle circumscribing thebase.